3M Cold Shrink Rubber Splicing Kit 5552 for 5/8 kv Shielded to Shielded or Shielded to Non-Shielded Cables Instructions IEEE Std. No. 404 5 kv Class, 75 kv BIL 8 kv Class, 95 kv BIL! CAUTION Working around energized systems may cause serious injury or death. Installation should be performed by personnel familiar with good safety practice in handling electrical equipment. De-energize and ground all electrical systems before installing product. October 2013 3 78-8096-4738-7 Rev E
Kit Contents (3 splices per kit) 3 Cold Shrink Insulators (tapered ends) 3 Cold Shrink Splice Jackets 3 Rolls Scotch Electrical Semi-Conducting Tape 13 3 Scotch Electrode Wraps 13 6 Scotch Rubber Mastic Tape 2228 3 Rolls Scotch Linerless Rubber Splicing Tape 130C 3 Shielding Braid Sleeves 6 Constant Force Springs (solderless ground connector) 3 Cleaning Pad Kits 3 Instruction Sheets Note: Do not use knives to open plastic bags. Kit Selection Chart Note: Final determining factor is cable insulation diameter. Kit Number 5552 Primary Insulation O.D. Range 0.725" 1.175" (18,4 29,8 mm) Conductor Size Range (AWG & kcmil) Copper Aluminum 4/0 500 4/0 400 Table 1 Optional Grounding Accessory For use if splices are to be individually grounded (not included with splice kit) Kit Number Accessory 3M Ground Strap Assembly Kit No. 5552 3M Ground Strap Assembly GS-2 Packaged 3 per bag; 9 per carton. 2 78-8096-4738-7 Rev E
1.0 Prepare Cable 1.1 Clean cable jackets by wiping with a clean dry cloth for approximately 3 feet (1 meter) at each end. 1.2 Prepare cables using standard procedures. For Non-shielded Cable a. Wrap a marker tape band around cable jacket at a distance of 6" (152 mm) from cable end (Figure 1). b. Remove insulation from cable end at a distance of 1/2 the connector length plus 1/4" (6 mm) (Figure 1). 6 (152 mm) Remove 1/2 Connector Length Plus 1/4 (6 mm) Vinyl Tape Marker Cable Jacket And Insulation Cable Conductor Figure 1 For Tape Shielded Cable a. Remove jacket a distance of 8" (203 mm) (Figure 2). b. Remove tape shield a distance of 6 1/2" (165 mm) from cable end. c. Remove cable semi-con layer as shown. d. Remove cable insulation from cable ends for a distance of 1/2 connector length plus 1/4" (6 mm). 8 (203 mm) 6 1/2 (165 mm) 1/2 (13 mm) Remove 1/2 Connector Length Plus 1/4 (6 mm) Cable Metallic Shielding Cable Semi-Con Cable Insulation Cable Conductor Figure 2 78-8096-4738-7 Rev E 3
For Wire Shielded Cables a. Remove jacket a distance of 8" (203 mm) (Figure 3). b. Wrap 2 full wraps Scotch Electrical Semi-Conducting Tape 13 over ground wires, 1 1/2" (38 mm) from cable jacket ends (Figure 3). c. Bend ground wires back over 13 tape and cut off wires at jacket edge (Figure 3). d. Remove cable semi-con layer as shown (Figure 3). e. Remove cable insulation from cable ends for a distance of 1/2 connector length plus 1/4" (6 mm) (Figure 3). 1 1/2 (38 mm) 8 (203 mm) 1/2 (13 mm) Remove 1/2 Connector Length Plus 1/4 (6 mm) Ground Wires Scotch Electrical Semi-Conducting Tape 13 Cable Semi-Con Cable Insulation Cable Conductor Figure 3 For UniShield Cables a. Wrap a vinyl tape band around cable jacket at a point 6 1/2" (165 mm) from cable end and remove drain wires from semi-con jacket to leading edge of applied vinyl tape band (Figure 4). 6 1/2" (165 mm) Vinyl Tape Semi-Conductive Jacket Drain Wires Figure 4 4 78-8096-4738-7 Rev E
b. Cut-off shield drain wires to a length of 1 1/2" (38 mm) and fold back onto cable (Figure 5). Important: For instruction purposes, this end of the cut-off drain wires shall be considered as the END OF THE JACKETS for the remainder of this instruction. Note: c. Install hose clamp and on side of clamp closest to cable end, cut 80% through cable jacket (Figure 5). d. Remove jacket by pulling against hose clamp. DO NOT BELL SEMI-CON JACKETS (Figure 5). Jacket may separate into two layers. Remove both layers of black semi-con jacket. e. Remove hose clamp. f. Remove cable insulation from cable end for a distance of 1/2 connector length (Figure 5). 1 1 1/2 (38 mm) Cut Jacket Remove 1/2 Connector Length Plus 1/4 (6 mm) Semi-Conductive Jacket Hose Clamp Vinyl Tape Wrap Drain Wires Figure 5 2.0 Slide Splice Components onto Cable 2.1 Slide cold shrink tubes and shielding braid sleeve onto cables. a. Slide cold shrink jacket (longer, non-tapered tube) onto one cable (Figure 6). Note: For shielded to non-shielded splices, the shielding braid sleeve is not used. b. Expand diameter of shielding braid sleeve by pushing in at ends (to shorten length) and slide onto other cable (Figure 6). c. Slide cold shrink insulator (tapered ends) onto cable (behind shielding braid sleeve if used) (Figure 6). Cable A Cable B Loose Tail End Loose Tail End Cold Shrink Jacket Cold Shrink Insulator Shielding Sleeve Figure 6 2.2 Clean exposed cable insulations with solvent cleaning pads. CAUTION: DO NOT allow solvent to touch cable semi-con. 78-8096-4738-7 Rev E 5
3.0 Install Connector 3.1 Install connector per manufacturer's directions. Note: Connector length must not exceed maximum shown in Table 2. Copper Connector Length (maximum) Aluminum 4.3" (109 mm) 3.75" (95,3 mm) Table 2 3.2 See pages 12 and 13 if 3M Scotchlok Connectors are used. 4.0 Apply Electrode Wrap (Semi-con) 4.1 If a gap greater than 1/8" (3 mm) exists between the connector and cable insulation, fill with Scotch Electrical Semi- Conducting Tape 13 (DO NOT exceed height of connector). 4.2 FOR INDENT CRIMPED CONNECTORS ONLY: Fill connector indents with 13 tape (Figure 7). Fill Gaps Of Over 1/8 (3 mm) Scotch Electrical Semi-Conducting Tape 13 Figure 7 5.0 Apply Semi-Conductive Electrode Wrap 5.1 Remove liner from Scotch Electrode Wrap 13. Center electrode wrap (narrow end) over connector. Wrap around connector with sufficient tension to eliminate gapping and wrinkling. Continue wrapping until electrode wrap divides into 2 legs (Figure 8). Wrap To Here Scotch Electrode Wrap 13 Figure 8 6 78-8096-4738-7 Rev E
5.2 Individually wrap each leg of Scotch Electrode Wrap 13 over area at ends of connector and cable insulation. Apply with adequate tension so legs conform tightly onto cable insulation (Figure 9). Scotch Electrode Wrap 13 Stretch To Conform Tightly 6.0 Apply Wrap Insulation Maximum Length 6 1/4" (159 mm) Figure 9 6.1 Apply Scotch Rubber Mastic 2228 tacky side down toward cable (Figure 10). FOR 4/0 AWG, 250, 350, AND 400 KCMIL CABLES 1/2" (13 mm) 1/2" (13 mm) Cable Semi-Con Cable Insulation Scotch Rubber Mastic Tape 2228 (with tacky side toward cable) 4/0 AWG AND 250 KCMIL CABLE: Apply 2 half-lapped layers of 2228 rubber mastic over electrode wrap, starting and ending 1/2" (13 mm) from cable semi-cons. Stretch rubber mastic sufficiently to conform. 350 AND 400 KCMIL CABLE: Apply 1 half-lapped layer of 2228 rubber mastic over electrode wrap, starting and ending 1/2" (13 mm) from cable semi-cons. Stretch rubber mastic sufficiently to conform. FOR 500 KCMIL CABLES 1 Half-Lapped Layer Scotch Rubber Mastic Tape 2228 1" (25 mm) 1" (25 mm) Scotch Electrode Wrap 13 Scotch Rubber Mastic Tape 2228 (with tacky side toward cable) 500 KCMIL CABLE: Apply 1 half-lapped layer of 2228 rubber mastic over electrode wrap, starting and ending 1" (25 mm) beyond ends of electrode wrap. Stretch rubber mastic sufficiently to conform. Figure 10 78-8096-4738-7 Rev E 7
7.0 Install Cold Shrink 7.1 Slide cold shrink insulator short tube with (tapered ends) over connector area. Align end of insulator (not core) at Dimension A, Table 3 and (Figure 11). Conductor Size (AWG or kcmil) Copper Connector Dimension A Aluminum Connector 4/0 250 350, 400 500 1/2" (13 mm) 1/2" (13 mm) 3/4" (19 mm) 1" (25 mm) 1/2" (13 mm) 3/4" (19 mm) 3/4" (19 mm) --- Table 3 7.2 Remove core UNWINDING, COUNTER-CLOCKWISE (Figure 11). Note: An occasional tug of the core strand while unwinding will aid in core removal. Counter-Clockwise [A] Cable Semi-Con Cold Shrink Insulator Figure 11 7.3 FOR 8 kv RATING ONLY: Apply 2 half-lapped layers of stretched Scotch Linerless Rubber Splicing Tape 130C over the cold shrink insulator between the end tapers (Figure 12). FOR 8 kv ONLY Scotch Linerless Rubber Splicing Tape 130C Figure 12 8 78-8096-4738-7 Rev E
8.0 Install Insulation Shield 8.1 IMPORTANT: Do the following steps that pertain to either shielded to shielded or shielded to non-shielded cables. For Shielded to Non-Shielded Cables a. Starting 1/4" (6 mm) on cable's metallic shielding (i.e. tape, wire or unishield ) apply 2 half-lapped layers of Scotch Electrical Semi-Conducting Tape 13 over the end of the cold shrink insulator for a total wrapped distance of 2 1/4" (57 mm) (Figure 13). Note: Install adequate ground lead to shield on the shielded cable side. (i.e. 3M Ground Strap Assembly GS Series), when rounding practices require. b. DO not use shielding braid sleeves included in kit for this installation. c. Proceed to Step 9.0, Install Jacket. 2 1/4" (57 mm) Non-Shielded Cable 1/4 (6 mm) Cold Shrink Insulator GS Series Ground Strap (Optional) Scotch Electrical Semi-Conducting Tape 13 Figure 13 For Shielded to Shielded Cables a. Apply 1 half-lapped layer of 13 tape over insulation starting and ending 1/4" (6 mm) onto cable's metallic shielding (Figure 14). 1/4" (6 mm) 1/4" (6 mm) Cold Shrink Insulator Scotch Electrical Semi-Conducting Tape 13 Figure 14 78-8096-4738-7 Rev E 9
8.2 Center shielding braid sleeve over Scotch Electrical Semi-Conducting Tape 13. 8.3 Install a constant force spring at one end; position spring over cable metallic shield next to cut-off cable jacket. With thumb, hold coil in place over sleeve (rolled up coil should be facing away from you). Pull coil around cable for one wrap only (Figure 15). Note: UNISHIELD CABLE ONLY: Reminder that cut-off ends of drain wires represent end of cable jacket. Pull Coil (Face Down) Around Cable Locate Over Shield Next To Cable Jacket Constant Force Spring Shielding Braid Sleeve Figure 15 8.4 Fold ends of sleeve wires back over the single wrap of coil, then continue applying coil allowing it to wrap around the wires and itself (Figure 16). Note: Cinch (tighten) coil after final wrap. 8.5 Using hand to pull on loose end of shielding braid sleeve, pull so sleeve snugs firmly against splice. Secure it into position with second constant force spring applied in the same manner as the first (Figure 16). 8.6 Overwrap constant force spring and ends of folded back shielding braid with a layer of 13 tape or vinyl electrical tape (Figure 16). Fold Back Overwrap with Scotch Constant Force Spring Electrical Semi-Conducting Tape 13 Figure 16 10 78-8096-4738-7 Rev E
Optional If splice is to be individually grounded, 3M Ground Strap Assemblies GS Series are ordered separately (see front cover for kit selection). a. Install the ground strap assembly on selected splice end. b. Unwrap 1" to 2" (25 to 50 mm) of coil. c. Lay the ground strap along cable with the extended coil facing downward (away from you--see figure below). Splice Kit s Constant Force Spring End Of Shield Braid Coil (Facing Downward) (Optional) 3M Ground Strap Assembly GS Series d. Hold coil in place with thumb. Pull coil around cable allowing it to unwrap and rewrap around the shield braid and itself. Note: Cinch (tighten) the applied coil after final wrap. 78-8096-4738-7 Rev E 11
9.0 Install Jacket 9.1 Apply 2 wraps of Scotch Rubber Tape Mastic 2228 around cable jackets (tacky side toward jacket), 1/2" (13 mm) from jacket ends (Figure 17). BRAID SHIELD NOT USED ON SHIELDED TO NON-SHIELDED SPLICES 1/2" (13 mm) 1/2" (13 mm) Scotch Rubber Mastic Tape 2228 (2 wraps) Figure 17 Optional If 3M Ground Strap Assembly GS Series was installed. a. Carefully bend ground strap away from cable jacket. b. Apply 1 wrap of 2228 rubber mastic around cable jacket, 1/2" (13 mm) from jacket end (Figure 17). c. Press ground strap back down onto rubber mastic wrap, then apply second wrap of rubber mastic over ground strap and around cable. 9.2 Slide cold shrink splice jacket into position over splice. Align end of cold shrink jacket (not core) so that previously applied 2228 rubber mastic wrap is completely covered (Figure 18). Note: An occasional tug of the core strand while unwinding will aid in core removal. Counter-Clockwise Scotch Rubber Mastic 2228 Align End Of Cold Shrink Jacket Cold Shrink Jacket Figure 18 Optional If GS ground strap assembly was installed, attach external ground wire to ground strap. 12 78-8096-4738-7 Rev E
Tooling Index Copper Connectors CRIMPING TOOL/DIE SETS (NO. OF CRIMPS/END) Splice Kit No. Cable Size 3M Scotchlock Copper Connector Number Length inches (mm) Burndy Corporation Thomas & Betts Corporation Square D. Co. Anderson Div MD6 MY29 Y34A Y35, Y39, Y45*, Y46* TBM 5 TBM 8 TBM 15 VC6 3, VC6 FT** 6 10001 4 10002 175 1.75 (44,4) 6AWG (1) U5CR T (1) Blue (1) Blue (1) Universal (1) W161 (1) 4AWG (1) A4CR (1) U4CR T (1) Grey (1) Grey (1) Universal (1) 2 10003 W162 (2) 2AWG (1) A2CR (1) U2CR T (2) Brown (1) Brown (1) 33 (1) Universal (2) 1 10004 1.88 (47,6) 1AWG (1) A1CR (1) U1CR T (2) Green (1) Green (1) 37 (1) Universal (2) 1/0 10005 W163 (2) 1/0 (1) A25R (1) U25R T (1) Pink (2) Pink (2) 42 (2) Universal (1) 5551 2/0 10006 2.00 (50,8) 11006 3.13 (79,4) W241 (2) ) 2/0 (1) ) A26R (1) ) U26R T (2) ) Black (2) ) Black (2) ) 45 (1) ) Universal (1) ) W241 (3) 2/0 (2) A26R (2) U26R T (3) Black (3) Black (3) 45 (2) Universal (2) 3/0 10007 2.13 (54,0) 11007 3.13 (79,4) W243 (2) ) 3/0 (1) ) A27R (1) ) U27R T (2) ) Oran ge (2) Oran ge (2) 50 (1) ) Universal (1) ) W243 (3) 3/0 (2) A27R (2) U27R T (3) Orange (3) Orange (3) 50 (2) Universal (2) 4/0 10008 2.13 (54,0) 4/0 11008 3.38 (85,8) BG (3) ) 4/0 (1) ) A28R (2) ) U28R T (2) ) Pur ple (2) ( Pur ple (2) ( 54H (2) ) Universal (2) ) BG (4) 4/0 (2) A28R (3) U28R T (3) Purple (3) Purple (3) 54H (3) Universal (3) 250 10009 2.25 (57,2) 11009 3.38 (85,8) W166 (3) ) 250 (1) ) A29R (2) ) U29R T (2) ) Ye llow (2) ) Ye llow (2) ) 62 (2) ) Universal (2) ) W166 (4) 250 (2) A29R (3) U29R T (3) Ye llow (3) Ye llow (3) 62 (3) Universal (3) 5552 300 10010 2.25 (57,2) 11010 4.13 (104,8) A30R (2) ) U30R T (2) ) White (2) ) 66 (2) ) Universal (2) ) A30R (3) U30R T (3) White (3) 66 (3) Universal (3) 350 10011 2.38 (60,4) 11011 4.13 (104,8) A31R (2) ) U31R T (2) ) Red (3) ) 71H (3) ) A31R (3) U31R T (3) Red (4) 71H (4) 500 10014 2.88 (73,0) 500 11014 4.63 (117,5) A34R (2) ) U34R T (2) ) Brown (3) ) 87H (3) ) A34R (4) U34R T (3) Brown (4) 87H (4) 5553 750 1000 10019 3.38 (85,8) 11019 5.88 (149,2) 10024 3.88 (98,4) 11024 6.13 (155,6) Y39, Y45, Y46: U39R T (3) 106H (3) Y39, Y45, Y46: U39R T (5) 106H (4) Y45: S44R T (4) Y46: P44R T (4) 125H (3) Y45: S44R T (6) Y46: P44R T (6) 125H (4) *Y45 and Y46 accept all Y35 dies ( U Series). For Y45 use PT6515 adapter. For Y46 use PUADP adapter. **Anderson VC6 3 and VC6 FT r equire no die set. 78-8096-4738-7 Rev E 13
Tooling Index Copper/Aluminum Connectors Splice Ki t Cable Size No. Size S 3M Scotchlock Aluminum Connector Number Length inches (mm) MD6 MY29 Y34A CRIMPING T OOL/DIE SETS (NO. OF CRIMPS/END) Burndy Corporation Thomas & Betts Corporation Y35, Y39, Y45*, Y46* Y1000** TBM 5 TBM 8 TBM 15 Square D. Co. Anderson Div VC6 3, VC6 FT** ITT Blackburn Co. Kearney Nat l Inc. OD5 8 Type O 6 20001 1.62 (41,1) W161 (1) 6AWG (1) A6CAB (1) U6CABT (1) Universal (1) Grey (1) Grey (1) 29 (1) Universal (1) BY19 (3) J (3) 4 20002 1.88 (47,8) W162 (3) 4AWG (1) A4CAB (1) U4CABT (1) Universal (1) Green (2) Green (2) 37 (1) Universal (1) BY53 (3) P (3) 2 20003 2.00 (50,8) W163 (3) 2AWG (1) A2CAB (1) U2CABT (1) Universal (1) Pink (2) Pink (2) 42H (2) Universal (1) BY23 (3) 1/2 (3) 5551 1 20004 2.00 (50,8) W163 (3) 1AWG (1) A1CAR (1) U1CA RT (1) Universal (1) Gold (2) Gold (2) 45 (1) Universal (1) BY23 (3) 1/2 (3) 1/0 20005 2.12 (53,8) W241 (2) 1/0 (1) A25AR (1) U25AR T (1) Universal (1) Tan (2) Tan (2) 50 (1) Universal (1) BY25 (3) 5/8 1 (3) 2/0 20006 2.31 (58,7) BG (4) 2/0 (1) A26AR (2) U26AR T (2) Universal (1) Olive (2) Olive (2) 54H (2) Universal (2) BY31C (3) 5/8 1 (3) 3/0 20007 2.62 (66,5) W166 (4) 3/0 (1) A27AR (2) U27AR T (2) Universal (1) Ruby (2) Ruby (2) 60 (2) Universal (2) 737 (3) 4/0 20008 2.75 (69,9) W660 (4) 4/0 (2) A28AR (2) U28AR T (2) Universal (1) White (4) 66 (4) Universal (2) BY35C (4) 840 (4) 250 20009 2.94 (74,7) W249 (3) A29AR (2) U29AR T (2) Red (3) 71H (2) Universal (2) 5552 300 20010 3.12 (79,2) A30AR (2) U30AR T (2) Blue (4) 76 (1) 350 20011 3.38 (85,9) U31AR T (2) Brown (4) 87H (2) 400 20012 3.75 (95,3) U32AR T (4) 94H (1) 500 20014 3.88 (98,6) U34AR T (4) 106H (3) 600 20016 4.12 (104,6) U36AR T (4) 115H (2) 5553 750 20019 4.62 (117,3) 800 20020 4.75 (120,7) Y39, Y45, Y46: U39AR T 2 (4) Y45: S40AR T (4) Y46: P40AR T (4) 125H (3) 125H (3) 1000 20024 5.25 (133,4) Y45: S44AR T (4) Y46: P44AR T (4) *Y45 and Y46 accept all Y35 dies ( U Series). For Y45 use PT6515 adapter. For Y46 use PUADP adapter. **Anderson VC6 3 and VC6 FT and Burndy Y1000 r equire no die set. 78 8096 4637 1 (B ) 13 14 78-8096-4738-7 Rev E
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3M Scotch and Scotchlok are trademarks of 3M Company. UniShield is a trademark of General Cable Technologies Corporation. Important Notice All statements, technical information, and recommendations related to 3M's products are based on information believed to be reliable, but the accuracy or completeness is not guaranteed. Before using this product, you must evaluate it and determine if it is suitable for your intended application. You assume all risks and liability associated with such use. Any statements related to the product which are not contained in 3M's current publications, or any contrary statements contained on your purchase order shall have no force or effect unless expressly agreed upon, in writing, by an authorized officer of 3M. Warranty; Limited Remedy; Limited Liability. This product will be free from defects in material and manufacture for a period of one (1) year from the time of purchase. 3M MAKES NO OTHER WARRANTIES INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. If this product is defective within the warranty period stated above, your exclusive remedy shall be, at 3M's option, to replace or repair the 3M product or refund the purchase price of the 3M product. Except where prohibited by law, 3M will not be liable for any indirect, special, incidental or consequential loss or damage arising from this 3M product, regardless of the legal theory asserted. 3 Electrical Markets Division 6801 River Place Blvd. Austin, TX 78726-9000 800.245.3573 Fax 800.245.0329 www.3m.com/electrical Please Recycle. Printed in USA. 3M 2013. All Rights Reserved. 78-8096-4738-7 Rev E